US-12623874-B1 - Paper web winding: roll quality improvement through the maximization of coupling between drive rolls and driven built paper roll

Abstract

A System and Method for Adaptive Paper Web Winding that adjusts Operational Parameters, including torque, pressure, tension, acceleration, Jerk Rate, and sheet speed, in response to Operational Data and feedback. The system, in one embodiment, comprises a Front Drum with adjustable torque control, a Rider Roll with variable pressure regulation, an Unwind Section with tension control, and a Control Unit configured to maximize coupling between drive rolls and driven built paper roll. The method involves detecting the Coefficient of Friction of a Paper Web, then adjusting Operational Parameters in response to Operational Data and feedback. This invention improves efficiency and reliability in paper winding operations by automating adjustments to accommodate variations in the Coefficient of Friction of a Paper Web.

Inventors

• Stephen Donald Pittman

Assignees

• Stephen Donald Pittman

Dates

Publication Date

20260512

Application Date

20250110

Claims (20)

1. 1 . An adaptive winding system comprising: one or more drive rolls; one or more sensors configured to detect actual web speed; and a control unit configured to detect slippage by comparing the actual web speed to the speed of the one or more drive rolls, and to adjust one or more operational parameters based on real-time feedback from the one or more sensors to restore frictional engagement.
2. 2 . The adaptive winding system of claim 1 , wherein the one or more operational parameters include torque, pressure, tension, web speed, acceleration rate, jerk rate, or a combination thereof.
3. 3 . The adaptive winding system of claim 1 , further comprising a rider roll configured to apply variable pressure on a built roll to maintain frictional engagement.
4. 4 . The adaptive winding system of claim 1 , wherein the one or more sensors include a non-contact web speed sensor, a tension sensor, or a combination thereof.
5. 5 . The adaptive winding system of claim 1 , wherein the one or more operational parameters are adjusted in response to one or more machine learning algorithms.
6. 6 . The adaptive winding system of claim 1 , further comprising a communication system configured to provide real-time visualizations of system performance metrics, predictive alerts, or a combination thereof, for potential slippage, misalignment, or a combination thereof.
7. 7 . A method for an adaptive winding system comprising: detecting slippage between a web and one or more drive rolls by comparing data from one or more sensors; and dynamically adjusting one or more operational parameters to restore frictional engagement between the web and the one or more drive rolls.
8. 8 . The adaptive winding system of claim 1 , wherein slippage conditions between a web and a rotating component are detected by comparing operational data from one or more sensors monitoring actual web speed to operational data from one or more sensors monitoring drum speed, and adjustments to operational parameters are performed in real time.
9. 9 . The adaptive winding system of claim 1 , further comprising an unwind section configured to regulate web tension upstream of a built roll using feedback from tension sensors and unwind motor speed sensors.
10. 10 . The adaptive winding system of claim 1 , wherein adjustments include recalibrating acceleration rate, jerk rate, or a combination thereof, to prevent slippage.
11. 11 . The method of claim 7 , wherein the adjusting uses one or more machine learning algorithms to analyze one or more patterns in operational data and adjust one or more operational parameters in response to the operational data.
12. 12 . The method of claim 7 , further comprising logging operational data for creation, optimization, or a combination thereof, of winding recipes.
13. 13 . The method of claim 7 , further comprising modifying rider roll pressure based on feedback from one or more sensors.
14. 14 . The method of claim 7 , wherein detecting slippage includes identifying when a front drum speed exceeds a back drum speed, and dynamically adjusting includes adjusting front drum torque to restore frictional engagement.
15. 15 . The method of claim 7 , wherein detecting slippage includes identifying when a back drum speed exceeds the actual web speed, and dynamically adjusting includes reducing unwind tension to restore frictional engagement.
16. 16 . The method of claim 7 , further comprising using one or more machine learning algorithms to predict adjustments to operational parameters based on historical operational data for different paper types, environmental conditions, or a combination thereof.
17. 17 . A system comprising: a drive roll; a sensor configured to measure web speed; and a control unit to detect slippage based on a discrepancy between the measured web speed and the drive roll speed, and to adjust a parameter accordingly.
18. 18 . The adaptive winding system of claim 1 , wherein the control unit uses one or more machine learning algorithms to analyze patterns in operational data and adjust one or more operational parameters to restore frictional engagement.
19. 19 . The adaptive winding system of claim 1 , further comprising a memory configured to log operational data for creation, optimization, or a combination thereof, of winding recipes.
20. 20 . The adaptive winding system of claim 1 , wherein the control unit is configured to detect vibrations, interweaving, or a combination thereof, based on real-time feedback from one or more sensors.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims no priority to any prior application. FIELD OF THE INVENTION The present invention relates to material winding systems for paper products. It introduces an adaptive system that dynamically adjusts Operational Parameters such as torque, pressure, tension, acceleration and Jerk Rate, or sheet speed to maximize coupling between drive rolls and the driven built paper roll. The system and method addresses challenges unique to paper materials, including, but not limited to, unexpected Slippage, Interweaving, excessive vibration, and operational inefficiencies. BACKGROUND OF THE INVENTION Paper manufacturing and processing industries rely on material winding systems to produce rolls of paper and its derivatives, such as coated sheets, uncoated sheets, or laminated paper. The quality of these rolls depends on maintaining proper Frictional Engagement between the paper surface and drive rolls. Standard industry practice is to allow Slippage (dynamic Coefficient of Friction). The goal of this invention is to maximize the Frictional Engagement of the drive rolls with the driven built roll by eliminating slip and maintaining a static coefficient of friction. Currently, the industry standard is to rely on predefined “recipes” to manage winding operations. These recipes specify variable arrays such as front drum torque and Rider Roll pressure profiles to accommodate different paper types. However, this approach lacks flexibility and fails to account for real-time variations in material properties or environmental conditions like humidity. As a result, issues such as Interweaving, Slippage, excessive vibration, and misalignment frequently occur during the winding process. These problems not only compromise roll quality but also increase downtime and operational inefficiencies. Existing solutions for improving Frictional Engagement during the winding process often involve applying a metal spray to create a “traction coating” to the drive drums. While this method increases the friction coefficient of the drive drums, it comes with significant drawbacks. The traction coating frequently leaves indents or marks on the paper surface, compromising the quality of the final product. This is particularly problematic for paper products requiring smooth or uniform finishes, such as coated or laminated sheets. Additionally, these coatings may wear unevenly over time, leading to inconsistent performance and necessitating frequent maintenance. It is clear that additional innovation is needed. Inventor'S Expertise The inventor, an electrical engineer with more than four decades of experience in the paper industry, has extensive knowledge of material winding systems and their operational challenges. This expertise has informed the development of this Adaptive Winding System, addressing long-standing inefficiencies in Paper Web winding processes. SUMMARY OF THE INVENTION This invention provides an Adaptive Winding System tailored for paper products and their derivatives. It dynamically adjusts key operational variables-Front Drum torque (FDT), Rider Roll pressure (RRP), unwind tension (UT), Acceleration Rate and Jerk Rate, and sheet speed—to optimize Frictional Engagement during the winding process. The system includes: A Front Drum with adjustable torque control and regulation;A Back Drum, the winder speed masterA Rider Roll with variable pressure control and regulation;An Unwind Section with tension control and regulation;A Control Unit that processes Sensor Operational Data to dynamically maximize coupling between drive roll and driven paper roll. By automating adjustments in real time, operators benefit from a safer and more streamlined process, leading to greater job satisfaction. The Adaptive Winding System significantly enhances the efficiency and reliability of paper winding operations. Additionally, the percentage of high-quality rolls increases and the percentage of defective rolls decreases. The automated nature of the system allows it to react dynamically to Sensor feedback, ensuring optimal performance and consistent roll quality. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram illustrating the key components of the adaptive material winder system: UW: (100) Unwind Section-Incoming Jumbo roll to be slit into smaller rolls. Variable diameter, regulates web tension;T: (101) Tension Sensor-Measures web tension between UW and BD;SS: (102) Non-contact Sheet Speed Sensor-Speed measurement of the sheet;BD: (103) Back Drum-Winder speed control Master roll;FD: (104) Front Drum-Adjustable torque follower of Back Drum;BR: (105) Built Roll-Roll created during the winding process;RR: (106) Rider Roll-Applies variable force down onto the Built Roll (BR);UWSS: (107) Unwind Motor Speed feedback Sensor;BDSS: (108) Back Drum Motor Speed feedback Sensor;FDSS: (109) Front Drum Motor Speed feedback Sensor;CU: (110) Control Unit-Processes Sensor Operational Data to detec